Programmable Reel Flange Sensor

The present application is a continuation of U.S. patent application Ser. No. 17/943,326, filed on Sep. 13, 2022, currently pending, which claims priority from U.S. Provisional Application Ser. No. 63/261,228 filed on Sep. 15, 2021. Each of the applications listed above is expressly incorporated herein by reference in their entirety.

In general, the present invention relates to an apparatus and or system used to coil lengths of elongated materials onto a spool and or reel. More particularly, the present invention provides an improved coiling by using a computer and sensors to detect and manage the turnaround point on the traverse while winding.

In general, lengths of material that are usually relatively long and flexible are wound on large reels and or spools by a manufacturer. It is known for redistribution to take these large reels and or spools of materials into smaller amounts for redistribution. The machines associated with such are often referred to as automatic cut and transfer coiling and or spooling machines. Coiling is typically a reference to taking the elongated material from a large spool and or reel to a smaller desired length for redistribution and wrapping it freely into a coil with no spool and or reel. Spooling is typically a reference to taking the elongated material from a large spool and or reel to a smaller desired length for redistribution then wrapped around another spool and or reel for redistribution.

Current methods in the prior art use manual adjustable limit switches that require adjustment for each reel and or spool width and diameter for knowing when to reverse the traverse on the barrel of the reel and or spool as the elongated material is being fed onto the reel and or spool. This method manually adjusts limit switches that require adjustment for each reel width and diameter. This requires entry into the machine, which obviously possesses a potential safety hazard to the operator of the machine,

Furthermore, during spool and or reel changeovers, it is often the case that a new spool and or reel is not placed on the mandrel in the exact same position as the spool and or reel being replaced. Normally this means that a worker must readjust the end stops on the traverse to make sure the traverse reverses at the correct point by just using their eye, which can also obviously lead to non-precise adjustments.

Thus, there is a need for a new and improved coiling method, which provides precise winding of the elongated material by improving the winding process. It is desirable to fill these needs with a reliable alternative that is affordable and functional. The above discussed limitations in the prior art are not exhaustive. The current invention provides an inexpensive, time saving, more reliable apparatus, method, and system where the prior art fails.

In view of the foregoing disadvantages inherent in the known types of spooling and coiling systems now present in the prior art, the present invention provides a new and improved apparatus, system, and method of using the same. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved spooling and or coiling system for use with elongated materials, which has all the advantages of the prior art devices and none and or fewer of the disadvantages.

It is, therefore, contemplated that the present invention is an apparatus, system, and method for a new and improved spooling and or coiling system during the winding process. It is contemplated to provide electrical sensors mounted on the traversing mechanism to detect flanges of different width or reel and spools as the flanges are approached during winding that provides an automatically turnaround point without human intervention and is computer controlled with communication from the sensor.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in this application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

Therefore, it is an object of the present invention to provide a new and improved spooling and or coiling apparatus, system, and method for use with elongated materials where it is desirable to have a precise traverse utilizing sensors and a computer during the winding process.

Furthermore, an object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method that eliminates the manual step of adjustment thus saving time and enabling operators to manage more winding stations.

Another object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method, which may provide neatly wound rows of product without overlapping, excessive gaps between rows, consistent product orientation with no “roll-overs”, and no tangled rows.

Still another object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method, which does not crush or distort elongated materials with a pile.

It is a further object of the present invention to provide a new and improved spooling and or coiling apparatus, system, and method, which is of a durable and reliable construction and may be utilized in numerous types of coiling applications.

An even further object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method, which benefits from a low cost of manufacture that accordingly results in a low price of sale to the consuming industry, thereby making such a system economically available to those in the industry.

Still another object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method, which provides all the advantages of the prior art while simultaneously overcoming some of the disadvantages normally associated therewith.

Yet another object of the present invention is to provide a new and improved spooling and or coiling apparatus, system and method that increases safety and removes the human element from having to climb into a machine to set traverse limits thereby making the process with improved ergonomics.

Another object of the present invention is to provide a new and improved spooling and or coiling apparatus, system, and method, which may automatically adjust for different reel and spool widths, sizes, and so forth.

It is a further object of the present invention to provide a new and improved spooling and or coiling apparatus, system, and method that is programmable for offsets based on material size for setting turnaround points and increases repeatability for flange limits of various reels and or spools.

These, together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages, and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

Referring to the illustrations, drawings, and pictures, reference charactergenerally designates a new and improved spooling and or coiling apparatus, system, and method of using the same constructed in accordance with the present invention. Inventionis generally used with elongated materials needing to be made into smaller segments for distribution from a larger spool and or reel. Elongated materials may be but are not limited to plastic profiles, such as but not limited to hollow profiles, flexible extrusions, hoses, electrical cables, steel cables, wire cables, felt, and so forth. For purposes of convenience, the reference numeralmay generally be utilized for the indication of the invention, portion of the invention, preferred embodiments of the invention and so on. It is also to be understood that inventionshould not be considered limited to just spooling and coiling and the terms should not be considered to limit the invention to such.

Inventionmay comprise a frame, a removable reelhaving a barrelbetween a first flangeand a second flange, a traverse feed system, and a computer control. Inventionalso contemplates mounting a first sensorand second sensoron traverse feed systemfirst side or endand second side or end, respectively.

First sensorand second sensorare in communication with computer controlfor sensing when traverse feed systemon frameis nearing first flangeand second flange, respectively. First sensorand second sensormay utilize lasers It is also contemplated that numerous sensors may be utilized.

First sensorand second sensormay be mounted as close to the tangent point of the reelas possible. First sensorand second sensormay be mounted to traverse feed systembut above the framegetting as close to the reeltangent pointas possible.

Inventioncontemplates:

1) Operator selects a recipe which may include core diameter, flange diameter, elongated material diameter, reel width, dwell, length to wind and so forth;

2) Operator then picks side to send home (either side);

3) Traverse then goes home and moves in a selected direction looking for flange greater than about 90% of recipe original diameter, flange found, moves an offset distance (pre-configured distance from sensor to center less 1/pipe diameter) for attachment, then turn-around position recorded, if end of travel found before flange, then reverse to find flange;

4) Operator attaches pipe to reel;

5) Operator presses start;

6) Winder winds first layer, reel turns at selected winding speed or torque, traverse follows at recipe pitch, looking for other flange, flange found, moves at pitch an offset distance (pre-configured distance from sensor to center less 1/pipe diameter), turn-around position recorded, recipe dwell begins; and

7) Winding continues like normal, using recorded turn-around points.

Additionally, reel core diameter and flange diameter could be measured automatically to help create reel recipe.

Therefore, inventioncontemplates a coiling system for coiling elongated materials on a removable reel comprising: said removable reel having a first flange, a second flange, a barrel between said first flange and said second flange; a traverse feed system having a first end with a first laser sensor for detecting said first flange, a second end with a second laser sensor for detecting said second flange; wherein said traverse feed system is adapted for coiling elongated material on said barrel between said first flange and said second flange; wherein said traverse feed system has a computer control in communication with said first laser sensor and adapted to reverse said traverse feed system when said first laser sensor detects said first flange; and wherein said traverse feed system said computer control is in communication with said second laser sensor and adapted to reverse said traverse feed system when said second laser sensor detects said second flange.

Changes may be made in the combinations, operations, and arrangements of the various parts and elements described herein without departing from the spirit and scope of the invention. Furthermore, names, titles, headings, and general division of the aforementioned are provided for convenience and therefore, should not be considered limiting.